Process of producing composite sheet and structure of the same

ABSTRACT

A process of producing composite sheet is presented, and the process comprises the steps of: (a) providing a plurality of metallic sheets; (b) bonding the metallic sheets with one another; and(c) finishing the bonded composite sheet that has a plurality of metallic layers. 
     In comparison to conventional single type/solid piece of building material, the present invention results in a dramatic cost reduction in various building industry. With the up-to-date technology, the strength of metallic composite sheet remains within structural grade parameter and meets related specifications. Manufacturers are benefited from the cheaper metallic sheet in the composition while enjoying the same quality look of the outer layer. Furthermore, a structure of the composite sheet is also presented in the present invention.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a kind of composite sheet that can beused as building and industrial material. In particular, it relates to aprocess of producing composite sheet and a structure of the same.

2. Description of the Related Art

Please refer to FIG. 1, representing a typical structure plan oftraditional composite sheet, wherein the traditional composite sheetrepresents one kind of exterior cladding material in the buildingindustry. The process of producing a traditional composite sheetcomprises the steps of (a) putting some plastic materials into anextruder which extrudes and heats the plastic materials (i.e. resin)until the plastic materials are melted; (b) the melted plastic materialsare transported to a mold to become a flat core layer 1 a of thecomposite sheet; (c) provide two metallic surfaces layers 2 a to bondwith the core layer 1 a.

As shown in FIG. 1, the structure of a traditional composite sheetincludes the core layer 1 a, and the two surface layers 2 a. The corelayer 1 a is sandwiched between the two surface layers 2 a.

Because quantities of easily accessible natural resources (specificallymetals) on Earth are decreasing, the cost of the composite sheet made ofexotic metals will be more and more expensive. However, if we simplydecrease the quantities of the more expensive metals for the metallicsurface layers 2 a and attempt to reduce the cost of the composite sheetin this simple fashion, the strength of the composite sheet would sufferand may not be enough to reach industry safety regulations.

SUMMARY OF THE INVENTION

One particular aspect of the present invention is to provide a processof producing a composite sheet and the structure of the same, thestrength of the composite sheet not only can satisfy the industry safetyregulation, but also the weight of the composite sheet can be reducedcompare to traditional composite sheet, and the cost of producing thecomposite sheet of the present invention can be effective reduced.

The process of producing a composite sheet, comprising the steps of: (a)providing a plurality of metallic sheets; (b) bonding the metallicsheets with one another; and (c) finishing the bonded composite sheethaving a plurality of metallic layers.

The structure of the composite sheet comprises a core layer and twosurface layers, wherein each surface layer has a plurality of metallicsheets, the metallic sheets bond with one another, the core layer andthe surface layers bond with each other, and the core layer issandwiched between the two surface layers.

This invention has several advantages: by carefully choosing thecomposite materials used to produce the surface layers, and coupled withthe present invention, thereby reducing the quantity requirement for themore expensive metal on the surface layers and the core layer of thecomposite sheet, and due to the bonding method of the present inventionthe strength of the composite sheet will still satisfy industry safetyregulation and the cost of producing the composite sheet can beeffectively reduced. The weight of the composite sheet can be light (dueto the fact that the more expensive metals are generally heavier), sothat it is very convenient for fabricator and installer to assemble manyof the composite sheets with each other.

For further understanding of the invention, reference is made to thefollowing detailed description illustrating the embodiments and examplesof the invention. The description is only for illustrating the inventionand is not intended to be considered limiting of the scope of the claim.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included herein enable a further understanding of theinvention.

Brief introduction of the drawings are as follows:

FIG. 1 is a plan of the structure of the traditional composite sheet.

FIG. 2 is a process for producing the composite sheet of the firstembodiment of the present invention.

FIG. 3 is a schematic view of the manufacturing equipments with respectto FIG. 2.

FIG. 4 is a process for producing the composite sheet of the secondembodiment of the present invention.

FIG. 5 is a schematic view of the manufacturing equipments with respectto FIG. 4.

FIG. 6 is a process for producing the composite sheet of the thirdembodiment of the present invention.

FIG. 7 is a process for producing the composite sheet of the forthembodiment of the present invention.

FIG. 8 is a process for producing the product of the composite sheet ofthe first embodiment of the present invention.

FIG. 9 is a schematic view of the manufacturing equipments with respectto FIG. 8.

FIG. 10 is a process for producing the product of the composite sheet ofthe second embodiment of the present invention.

FIG. 11 is a process for producing the product of the composite sheet ofthe third embodiment of the present invention.

FIG. 12 is a process for producing the product of the composite sheet ofthe forth embodiment of the present invention.

FIG. 13 is a process for producing the product of the composite sheet ofthe fifth embodiment of the present invention.

FIG. 14 is a plan of the structure of the composite sheet of the firstembodiment of the present invention.

FIG. 15 is a plan of the structure of the composite sheet of the secondembodiment of the present invention.

FIG. 16 is a plan of the structure of the composite sheet of the thirdembodiment of the present invention.

FIG. 17 is a perspective view of the structure of the composite sheet ofthe forth embodiment of the present invention.

FIG. 18 is a perspective view of the structure of the composite sheet ofthe fifth embodiment of the present invention.

FIG. 19 is a perspective view of the structure of the composite sheet ofthe sixth embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 2 and FIG. 3. A first embodiment of a process forproducing a composite sheet is presented, and the process comprises thesteps of:

(a) provide a plurality of metallic sheets 1 (top, middle, and bottommetallic sheets 1), wherein the metallic sheets 1 are coiled around acoiling roller group 21, and the metallic sheet 1 are made of aluminum,copper, steel, zinc, or titanium.

(b) Uncoil the metallic sheets 1 coiled around the coiling roller group21 (uncoiling can be done by motor (not shown) or any other powergenerating equipment, which is beyond the scope of the presentinvention), then as the metallic sheets are uncoiling, the top andbottom metallic sheets 1 are passed through a stretching roller group22, and the stretching roller group 22 extends, stretches, and flattensthe top and bottom metallic sheets 1.

(c) the middle metallic sheets 1 have top and bottom surfaces (here onnow referred as contact surfaces) respectively, place a plurality ofadhesive on the contact surfaces of the middle metallic sheets 1, heatthe adhesive films via a set of heating rollers 23 to form a pluralityof bonding layers on the contact surfaces respectively.

(d) the metallic sheets 1 are passed through a forming roller group 24;the forming roller group 24 includes a pair of first forming rollers241, a pair of second forming rollers 242, and a pair of third formingrollers 243. The metallic sheets 1 are pressed by the first formingrollers 241, the second forming rollers 242, and the third formingrollers 243 in sequence. The forming roller group 24 presses themetallic sheets 1 against the bonding layers in sequence, the metallicsheets 1 bond with each other via the bonding layers, and a compositesheet 3 having a plurality of metallic layers is finished. Though themetallic sheets 1 are not made of the more expensive metals, thestrength of the composite sheet 3, due to the bonding process, wouldstill satisfy industry safety regulation. In one embodiment, the top,middle, and bottom metallic sheets 1 in FIG. 3 are made of differentmaterials. Generally, the metallic sheets 1 that would eventually be the“presenting surface” or “top surface,” will be made of the moreexpensive metal, whereas the middle and bottom metallic sheets 1 wouldbe made of lighter and cheaper metal.

As shown in FIG. 4 and FIG. 5, represent the second embodiment of thepresent invention. Similar to FIGS. 2 and 3, except that a plurality ofadhesives are coated on the contact surfaces of the middle metallicsheets 1 by two adhesive applying units 25 (only 1 shown) with differentvertical positions, and the adhesives are bonding layers of thecomposite sheet 3.

The kinds of the adhesives used are not restricted, as long as theadhesives can bond the metallic sheets 1 with one another securely. Thetemperature of the set of heating rollers 23 depends on the adhesiveapplying units 25, and only needs to be high enough for proper adhesivebonding.

FIG. 6 is a process for producing the composite sheet of the thirdembodiment of the present invention. The bonding layers are formed bythe set of heating rollers 23. The radius of each third forming roller243 is longer than the radius of each second forming roller 242, and theradius of each second forming roller 242 is longer than each radius ofthe first forming roller 241. The metallic sheets 1 are pressed by thefirst forming rollers 241, the second forming rollers 242, and the thirdforming rollers 243 in sequence to contact with the bonding layersrespectively, and the metallic sheets 1 bond with each other via thebonding layers.

FIG. 7 is representing a process for producing the composite sheet ofthe fourth embodiment of the present invention. The bonding layers areformed by the two adhesive applying units 25. The radius of each thirdforming roller 243 is longer than radius of each second forming roller242, and the radius of each second forming roller 242 is longer than theradius of each first forming roller 241. The metallic sheets 1 arepressed by the first forming rollers 241, the second forming rollers242, and the third forming rollers 243 in sequence to contact with thebonding layers, and the metallic sheets 1 bond with each other via thebonding layers. Furthermore, we can bond the metallic sheets 1 with eachother by a metallic bonding process via heat conduction.

As shown in FIG. 8 and FIG. 9. A first embodiment for a process forproducing a product of the composite sheets is presented, and theprocess comprises the steps of:

(a) Mix some foaming agents and blowing promoters with a substrate, andthen put the substrate which is mixed with the foaming agents and the“blowing promoters” (A raw material for the manufacture of plastics, forexample, urea-formaldehyde resin) into an extruder 41. The extruder 41grinds, heats and extrudes the substrate to become an extruded liquidbar, and then the liquid bar are transported to a mold 42 to be flattenand become a core layer of the product, and then the core layer iscooled via a cooling apparatus (not shown). Wherein the kind of thesubstrate, the kinds of the foaming agents and the blowing promoters arenot restricted. The substrate can be made of polyethylene, orpolypropylene, or ethylene-vinyl acetate copolymer, the foaming agentscan be made of diazenedicarboxamide, and the blowing promoter can bemade of a zinc oxide or stearin cadmium.

(b) Apply adhesives (polymer film or liquid adhesive) onto the surfacesof the core layer by two adhesive applying units 43 with differentfeeding positions (top and bottom), the adhesives are the laminationagent of the product, and the kinds of the adhesives are not restricted.

(c) Provide two composite sheets 3, and the two composite sheets 3 arecoiled around two coiling rollers 44 with different vertical positions(top and bottom). Uncoil the two composite sheets 3, and the compositesheets 3 are transported to a forming roller group 45. The formingroller group 45 presses the composite sheets 3 to contact with thebonding layers, the composite sheets 3 are laminated to the core layer,the core layer is sandwiched between the two composite sheets 3, and thetwo composite sheets 3 are two surface layers of the productrespectively. Furthermore, the two surface layers can be coated withmany colors.

(d) cool the product via a cooling unit 46.

(e) guide the product to leave the cooling unit 46 via a guiding unit47.

(f) the guiding unit 47 guilds the product to move to a cutting unit 48,and the cutting unit 48 cut the product to length.

As shown in FIG. 10. A process for producing a product of the secondembodiment of the composite sheets is presented. FIG. 10's process issimilar to that of FIG. 8 with the following difference regarding and inplace of FIG. 8; please view in conjunction with FIG. 9: Provide anadhesive supply connecting with an adhesive shunt (not shown) which isbetween the mold 42 and the forming roller group 45. The adhesive shunthas two runners with different feeding positions (top and bottom). Afterthe core layer is formed after the mold 42, the two runners output andcoat the adhesives to both surfaces of the core. The adhesives are thelamination agents for surface metals of the product.

As shown in FIG. 11. A process for producing a product of the thirdembodiment of the composite sheets is presented. Similar to steps ofFIG. 8 with the following difference regarding and in place of FIG. 8b); please view in conjunction with FIG. 9: Provide some adhesive films.Place the adhesive films on the surfaces of the core layer, and heat andpress the adhesive films by a set of heating rollers (could be formingroller group 45 or a separate set of heating rollers) having hightemperature, and the adhesive films are found in-between the core &surface composite sheets to become adhesives, and the adhesives are thebonding layers of the product. As shown in FIG. 12. A process forproducing a product of the forth embodiment of the composite sheets ispresented: Provide the flat core layer made of polyethylene, orpolypropylene, or ethylene-vinyl acetate copolymer. Provide the two flatsurface layers made of composite sheets 3. Bend the core layer and thetwo surface layers by a beating tool, a punching tool, a stamper, or aroller group to become fretted or flexuous sheets, each metallic sheet 1of the surface layers includes a plurality of first base portions, aplurality of second base portions, and a plurality of bending portion,each first base portion's vertical position is different from eachsecond base portion's vertical position (for a visualization of what anembodiment of difference between base portion's vertical position,please see FIG. 15), and the bending portions are connected between thefirst base portions and the second base portions respectively, and thebonding power between the bended core layer and the bended surfacelayers are strengthened.

As shown in FIG. 13. A process for producing a product of the fifthembodiment of the composite sheets is presented. Provide the core layermade of the composite sheet 3. Provide the two flat surface layers madeof composite sheets 3. Bend the core layer by the beating tool, thepunching tool, the stamper or the roller group to become a fretted orflexuous sheet, and each metallic sheet 1 of the core layer includes aplurality of first base portions, a plurality of second base portions,and a plurality of bending portion, the bending portions are connectedbetween the first base portions and the second base portionsrespectively, the vertical position of each first base portion isdifferent from the vertical position of each second base portion. One ofthe two surface layers bonds with the first base portions, and the othersurface layer bonds with the second base portions.

As shown in FIG. 14. A structure of a composite sheet is presented, andthe structure of the composite sheet comprises a core layer 5, twosurface layers 6 and a plurality of bonding layers 7. The core layer 5and the surface layers 6 are three flat sheets. The core layer 5 issandwiched between the two surface layers 6, the core layer 5 is made ofpolyethylene, or polypropylene, or ethylene-vinyl acetate copolymer, andeach surface layer 6 has a plurality of metallic sheets 61. The bondinglayers 7 are made of adhesives. One of the bonding layers 7 are mountedbetween the metallic sheets 61 and the core layer 5, and the otherbonding layers 7 are mounted between the two metallic sheets 61 andbonds the metallic sheets 61 and core layer 5 together.

As shown in FIG. 15. A second embodiment of the structure of thecomposite sheet is presented. And the second embodiment of the compositesheet comprises a core layer 5′, two surface layers 6′ and a pluralityof bonding layers 7′. The core layer 5′ and the surface layers 6′ arefretted or flexuous sheets. The core layer 5′ is sandwiched between thetwo surface layers 6′, the core layer 5′ is made of polyethylene, orpolypropylene, or ethylene-vinyl acetate copolymer, and each surfacelayer 6′ has a plurality of metallic sheets 61′. Each metallic sheet 61′includes a plurality of first base portions 611′, a plurality of secondbase portions 612′, and a plurality of bending portion 613′, the bendingportions 613′ are connected between the first base portions 611′ and thesecond base portions 612′ respectively, the vertical position of eachfirst base portion 611′ is different from the vertical position of eachsecond base portion 612′. The bonding layers 7′ are made of adhesives.Two of the bonding layers 7′ are mounted between the metallic sheets 61′and the core layer 5″, and the other bonding layers 7′ are mountedbetween the two metallic sheets 61′, wherein the bonding layers 7′ bondsthe metallic sheets 61′ and core layer 5′ respectively.

As shown in FIG. 16. A third embodiment of the structure of thecomposite sheet is presented. And the third embodiment of the compositesheet comprises a core layer 5″, two surface layers 6″ and a pluralityof bonding layers 7″. The core layer 5″ is a flexuous sheet. The corelayer 5″ is sandwiched between the two surface layers 6″, the core layer5″ has a plurality of metallic sheets 51″, and each metallic sheets 51″includes a plurality of first base portions 511″, a plurality of secondbase portions 512″, and a plurality of bending portion 513″, the bendingportions 513″ are connected between the first base portions 511″ and thesecond base portions 512″ respectively, the vertical position of eachfirst base portion 511″ is different from the vertical position of eachsecond base portion 512″ (in the shape of a square wave function as canbe seen from FIG. 16). The surface layers 6″ are two flat sheets, andeach surface layer 6″ has a plurality of metallic sheets 61″. Thebonding layers 7″ are made of adhesives. One of the bonding layers 7″are mounted between the metallic sheets 61″ and the core layer 5″, andthe other bonding layers 7″ are mounted between the metallic sheets 51″of the core layer 5″ and the metallic sheets 61″ of the surface layer 6″respectively.

As shown in FIG. 17. A forth embodiment of the structure of thecomposite sheet is presented, and the forth embodiment of the compositesheet comprises two core layers A and a plurality of bonding layers B,the two core layers A are one flexuous sheet and one flat sheet, andeach core layer A has a plurality of metallic sheets, and the metallicsheets bond with one another via some of the bonding layers B. Theflexuous sheet includes a plurality of first base portions A1, aplurality of second base portions A2, and a plurality of bending portionA3. The bending portions A3 are connected between the first baseportions A1 and the second base portions A2 respectively, the verticalposition for all the first portions A1 and the second portions A2 aredifferent, and the second base portions A2 bond with the flat sheet viaone of the bonding layers B which is between the flexuous sheet and theflat sheet.

As shown in FIG. 18. A fifth embodiment of the structure of thecomposite sheet is presented. The number of the core layer A is two, andthe core layers A are two flexuous sheets, and each core layer A aremade of metallic sheets, and the metallic sheets bond with one anothervia some of the bonding layers B. Each flexuous sheet includes the firstbase portions A1, the second base portions A2, and the bending portionA3. The first base portions A1 of one of the flexuous sheets bond withthe second base portions A2 of the other flexuous sheet via one of thebonding layers B which is between the two flexuous sheets.

As shown in FIG. 19. A sixth embodiment of the structure of thecomposite sheet is presented. The number of the core layer A is three,and the core layers A are two flexuous sheets and one flat sheet. Eachcore layer A are made of metallic sheets, and the metallic sheets bondwith one another via some of the bonding layers B. Each flexuous sheetincludes the first base portions A1, the second base portions A2, andthe bending portion A3. The first base portions A1 of one of theflexuous sheet and the second base portions A2 of the other flexuoussheet bond with the flat sheet via two of the bonding layers B which areamong the two flexuous sheets and the flat sheet respectively.

The present invention has the following characteristics: Even themetallic sheets 1 are not generally made of more expensive metals, thestrength of the composite sheet 3 should still satisfy industry safetyregulation, the cost of producing the composite sheet 3 can beeffectively reduced, the weight of the composite sheet 3 can be lightwhen compared to using traditional method, so that it is very convenientfor users to assemble many of the composite sheets 3.

The description above only illustrates specific embodiments and examplesof the invention. The invention should therefore cover variousmodifications and variations made to the herein-described structures andapplications of the invention provided if they fall within the scope ofthe invention as defined in the following appended claims.

1. A process of producing a composite sheet, comprising the steps of:(a) providing a plurality of metallic sheets; (b) bonding the metallicsheets with one another; and (c) finishing the bonded composite sheethaving a plurality of metallic layers.
 2. The process of producing thecomposite sheet as claimed in claim 1, wherein the metallic sheets arecoiled or uncoiled around a coiling roller group before bonding theplurality of the metallic sheets with one another.
 3. The process ofproducing the composite sheet as claimed in claim 1, wherein themetallic sheets are passed through a stretching roller group beforebonding the metallic sheets, and the stretching roller group extends,stretches, and flattens the metallic sheets.
 4. The process of producingthe composite sheet as claimed in claim 1, wherein the metallic sheetshave top and bottom contact surfaces, a plurality of adhesive films areplaced on the contact surfaces of one of the metallic sheets beforebonding the plurality of the metallic sheets with one another, and theadhesive films are heated by a set of heating rollers to becomeadhesives, and the adhesives are bonding layers of the composite sheet.5. The process of producing the composite sheet as claimed in claim 1,wherein the metallic sheets have contact surfaces, a plurality ofadhesives are coated on the contact surfaces of one of the metallicsheets by singular or multiple adhesive applying units before bondingthe plurality of the metallic sheets with one another, and the adhesivesare bonding layers of the composite sheet.
 6. The process of producingthe composite sheet as claimed in claim 1, wherein the plurality of themetallic sheets are passed through a forming roller group after one ofthe metallic sheets out of the plurality of metallic sheets has formedthe bonding layers, the forming roller group presses the metallic sheetsto contact with the bonding layers respectively, and the plurality ofmetallic sheets bond with each other via the bonding layers.
 7. Theprocess of producing the composite sheet as claimed in claim 6, whereinthe forming roller group includes a pair of first forming rollers withdifferent vertical positions, a pair of second forming rollers withdifferent vertical positions, and a pair of third forming rollers withdifferent vertical positions, therein the radius of each third formingrollers is longer than the radius of each second forming rollers, andthe radius of each second forming roller is longer than the radius ofeach first forming roller, the metallic sheets are pressed by the firstforming rollers, the second forming rollers, and the third formingrollers in sequence.
 8. The process of producing the composite sheet asclaimed in claim 1, wherein the metallic sheets are deformed by abeating tool, a punching tool, or a roller group to become flexuoussheets, and each flexuous sheet has a plurality of first base portions,a plurality of second base portions, and a plurality of bending portion,the bending portions are connected between the first base portions andthe second base portions, the vertical position of each first baseportion is different from the vertical position of each second baseportion, forming a square wave shape. 9-21. (canceled)